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Aditive Manufacturing of Flap Tracks based on Laser W-DED Process

  • Start: 01/04/2021
  • End: 31/05/2023

ADDIFLAP will develop a new concept of flap track system by combining a novel flap track support manufactured by Laser Wire Direct Energy Deposition (W-DED-LB) with a new design of carriage system based in sliding pad concept, free of maintenance Deployment of W-DED-LB process will be supported by numerical models and the online process monitoring & control, to stablish the manufacturing strategies to reduce distortion and achieve the suitable structural integrity. Sliding pad design for the flap carriage system will be based on self-lubricant surfaces-materials & processing- approach.
ADDIFLAP will reach TRL6 demonstrating the W-DED-LB performance in a real manufacturing environment, getting the final validation of the flap track structure under dynamic conditions. Also, the validation of a self-lubricant material which enable the redesign of the carriage system through a sliding concept will be carried out, under normal load and several sliding cycles. Wear on mobile surfaces will be stablished on the sliding pad in contact with the additive manufactured track
New manufacturing strategy of ADDIFLAP will impact the whole value-chain, improving the environmental impact and the industrial competitiveness: raw material saving, energy-efficiency and overall optimisation. W-DED’s CO2 emissions are only the 26% compared with CNC machining. On the other hand, it is expected a material saving of around 60% of titanium waste per component compared to machining.
AIMEN will develop the models for the simulation of the laser additive manufacturing by wire directed energy deposition (W-DED-LB process) of Ti alloys, particularly Ti grade 5 alloy, to reduce the distortion of the final bulk component. AIMEN will also works in the W-DED-LB process set up by optimizing the process parameters and work conditions (inert atmosphere), in order to manufacture the final demonstrator, the flap track component. Finally, AIMEN will perform a full test plan, including destructive and non-destructive tests to validate the manufacturing process according to the requirements stablished by the aeronautic sector for this kind of components.

  • Sectors: Aeronautical
  • Financing programme: CLEAN SKY 2
  • R&D&i: Additive manufacturing, Laser assisted processing, high power and high throughput laser processing
  • Partners: AC2T research GmbH
  • Acronym: ADDIFLAP
  • Ambit: International